Collapsible cellular carton



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coLLArasIBLE CELLULAR CARTON Filed April 7. 1954 s sheets-sheet zINVEN-ron 05E/u? L. t//A/Es Feb. 3, 1959 o. L. vlNEs coLL'APsIBLECELLULAR CARTON 3 Sheets--Sheetl 3 I Filed April 7, 1954 .INVENTOR 'l yCAR L. l//A/Es y `B y l MMQM/Jg@ IATTORNEYS United States PatentCOLLAPSIBLE 'CELLULAR 'CARTON Oscar L. Vines, 'New York, N. Y., assignorto Alfords Cartons, Ridgefield Park, N. I., a corporation of 'New JerseyApplication April 7, 1954, Serial No. 421,625

2 Claims. (Cl. 229-28) The present invention relates to a collapsiblecellular carton and carton blank. More particularly, the invention isconcerned with an improved collapsible paperboard egg carton and cartonblank.

Paperboard cellular cartons are preferably designed so that their majorpanels fold across the grain of the paperboard. This assures thatfoldable connections between the major panels are permanent and strong.It is the practice to provide compartmentati-on for such cellularcartons by incorporating partitions folding transverse to the majorpanels and, consequently, parallel to the grain of the paperboard. Sincepaperboard material i's more readily foldable along its grain,partitions transverse to t'ne major panels are weak and mustbe stiffenedl to provide suitable compartmentation.

The aforementioned conditions are critical in the case of collapsibleegg cartons for, unless suitable structural re-enforcement is providedfor the cross partitions, the eggs are likely to shift and break. lnaddition to prevention of longitudinal shifting, the cross partitionsshould also possess sufficient resiliency to accommodate, in a cellularmanner, eggs of varying size. An egg carton having cross partitions ofthe aforementioned characteristics is particularly necessary where it isdesired to sever a so-called 2 x 6 carton for sale of half of itscontents. Transverse severance of the carton exposes intermediate cellsand their cross partitions. It is therefore essential that suchintermediate cross partitions have the strength of carton end walls. Atthe same time, the erected cartons should possess sulcient strength forhandling and stacking. Here again, re-enforced cross partitions serve tosupport the major panels of the carton.

I have now devised a carton and carton blank of sufticient configurationas will allow mutuall support between the major panels and theircooperating partition panels, without increase either in the amount ofpaperboard used or in production costs for forming the blank and thecarton. In fact, the carton blank of my invention uses no morepaperboard than is normally used, and effects a substantial saving inthat a minimum number of knock-out sections need be removed from thecarton 2,872,096' aefenfed Feb. 3, 1959 side panel. A shelf panel isintegrally connected at its inner edge to the upper edge of each innerside panel and is adhesively connected at its outer edge to theproximate outer side panel. The width of each shelf panel is preferablygreater than the width of each bottom panel. A pair of oppositelyextending primary crosspartitions is formed from the full width of eachshelf panel, each primary cross partition being folded downwardly fromthe plane of its shelf panel about a transverse fold line. The primarycross partition panels in each pair thereof t preferably are resilientlymedially displaceable in opposite directions at their foldableconnections with theiry shelf panel to allow accommodation for articlesof varying size. At least one pair of secondary partitions is alsoformed in each shelf panel intermediate each pair of primary crosspartitions, and these secondary partitions are folded downwardly intothe erected carton about transverse fold lines spaced from one another adistance equal to their respective distance from the proximatetransverse fold line for the primary cross partitions. Lateral edgeportions of the primary cross partitions and the secondary partitionsare folded inwardly from the planes of the partitions as a result of thepartitions being folded into the carton about their respectivetransverse fold lines. These lateral edge portions become wedged againstthe inner and outer side panels and serve to stiften the partitionsagainst folding along the grain of the paperboard, which runs transverseto the integral connections for the major panels. Each bottom panel hastransverse slits therein for receiving the lower end of each primarycross partition of each pair thereof. A pair of lugs cut from eachbottom panel form continuous projections from the lower edge o-f eachinner side panel. A primary cross partition-locking flap preferablyfoldably connected to the bottom panel along an oblique transverse foldline otfset'from each transverse slit and converging in the directionthereof toward each outer side panel, allows gradual entry of eachprimary cross partition into each transverse slit and retains eachprimary cross partition in registry with the bottom panel to provide apartition having substantially the rigidity of an end wall. At least onetop cover panel provided with an integrally connected locking ap, havingtongues interlocking with the shelf panel, is supported on the shelfpanel to permit columnar loading of the cartons through intermediationof the inner side panels and the lugs, the stilfened partitions wedgedfrangibly connected along an interrupted longitudinal cut blank.Compared to cartons using equal amounts of l paperboard, my presentcarton possesses much greater over-all `stability in the major panelsand their c0operating partition panels. n v

My paperboard collapsiblecarton is characterized by a pair oflongitudinally connected abutting sections forming a pair of rows ofcells, with each row composed of at least one group of three cellsdefined by one pair of primary cross partitions and an intermediate pairof secondary partitions. The carton comprises a pair of inner sidepanels adhesively secured together in side-by-side relation. A bottompanel is integrally connected to the lower edge of each inner sidepanel, and an outer side panel is integrally connectedv to the outeredge of eachagainst the side panels offering support to the maj-orcarton panels.

The paperboard blank for the collapsible cellular carton of my inventionhas a pair of facsimile sections line. The major panels for eachfacsimile section of the blank comprises in integrally connectedinbo-ard succession the youter glue flap, the shelf panel, the innerside panel, the bottom panel preferably having a width less than thewidth of the shelf panel, the outer side panel preferably wider than theinner side panel and adapted to receive the outer glue flap injuxtaposition, the top cover panel, and the tongue flap. The tongue apsyfor said facsimile sections are laterally adjacent along theinterrupted longitudinal cut line.

-Each of the shelf panels are provided with at least one pair of thespaced oppositely extending primary cross partitions hinged to the shelfpanel by the primary transverse fold lines. Each of the shelf panels arefurther provided within a pair of the secondary partitions positionedintermediate the pair of primary cross partitions and hinged to theshelf panel by secondary transverse fold lines. The bottom panels havetransverse slits therein adapted to receive the lower end of eachprimary cross partition of each pair thereof. At least one pair of lugsare defined in the bottom panel by varched cut lines adjacent each ofthe short side panels. When the carton blank is glued and first foldedabout the short side panel and the bottom panel for each facsimilesection, and when the major panels -are again folded about the frangibleconnections between adjacent tongue panels, any knock-out sectionsremaining between the tongue iiaps are readily removable from a lateralextremity of the folded carton blank.

These and other features of the carton of my invention will be morefully understood by reference to the accompanying drawings in which:

Fig. l is a plan view of a carton blank of my invention;

Fig. 2 is a view of the blank of Fig. l after a 'first foldingoperation;

Fig. 3 Vis a view of the blank of Fig. 2 after a secondfoldingoper'ation in its assembly;

Fig. 4 is an end view of the resulting assembled carton;

Fig. 5 is a perspective view of a longitudinal portion of the cartonformed from the blank of Fig. l;

Fig. 6 is-a transverse sectional elevation of the erected carton takenalong line A-A of Fig. 5;

Fig, 7 is a longitudinal sectional elevation of the erected carton takenalong line B-B of Fig. 5; and

Fig. S is a plan view of modified carton blank of my invention.

Referring to Figs 1 3, the carton blank comprises a pair of facsimilesections 1 and 2 frangibly connected along an interrupted longitudinalcut line 3, each blank section being in turn subdivided transversely byan interrupted cut line 4 extending transversely thereacross. The grainof the paperboard runs transversely across the facsimile sections, asindicated by the arrows. The major carton panels extend longitudinallyof the blank and are integrally connected along longitudinal fold linesextending across the grain of the paperboard.

The major carton panels are arranged symmetrically about both sides ofthe interrupted longitudinal cut line 3 in each of `the facsimilesections 1 and 2, and are provided in inboard succession in the order ofan outer glue liap 6, a shelf panel 7, a short side panel 8, a bottompanel 9 having a width less than the width of the shelf panel 7, asecond side panel 16 wider than the side panel 8, a top c'over panel 11,and a tongue flap 12. The major panel portions at both sides ofthetransverse interrupted cut line 4 are likewise substantially identicalin each facsimile section. f

Each portion of the shelf panel 7 at both sides of the transverse cutline 4, for each of the blank sections 1 and 2, is provided with a pairof oppositelyestending primary cross partitions 15 and 16. Each pair ofthe primary cross partitions is defined by a pair of primary arched cutlines 18 and 19 extending across the full width of the shelf panel anddiverging longitudinally at their respective terminals 21, 22, 23 and 24as pairs of parallel cut lines for each primary cross partition. Theprimary cross partitions 15 and 16 are foldable from the plane of theshelf panel 7 along primary transverse fold lines 26 and 27 whichconnect the terminals of the arched cut lines, respectively.

Each of the primary transverse fold lines 26 and 27 includes atransverse cut line 30 offset therefrom in a direction opposite thedirection of the proximate arched cut line. rl'he short transverse cutline 3G vmay alternatively be olfset from its respective transverse foldline in the direction of its proximate arched cut line. In each case, ashort transverse cut line, such as the cut line 30, renders theproximate primary cross partition panel medially unsupported, whenfolded about its respective primary fold line, so as to resilientlyaccommodate eggs of varying size.

At least one pair of secondary partitions 32 and`33 is also formed ineach Shel-f panel so as to lie intermediate the primary cro'sspartitions 15 -and 16. Each pair of the secondary partitions is delinedby a central cut line 3S extending transversely across the full width ofthe Shelf panel and bisecting a pair of parallel longitudinal cut lines37 and 38 at the longitudinal edges of the shelf panel. The longitudinalcut lines 37 and 38 terminate in offset relation to the arched cut lines18 and 19, and, at their longitudinal extremities, join secondarytransverse fold lines 4l and 42 for the secondary partitions. Medialportions of the primary arched cut lines 18 and 19 preferably intersectthe secondary transverse fold lines 41 and 42 such that secondarypartitions 32 and 33 are medially unsupported, the secondary partitionsbeing supported at their lateral sides by webs in the shelf paneldelined by intersections of the transverse fold lines 41 and 42, and thearched cut lines 1S and 19.

At their lateral edges, each of the primary cross partitions 15 and 16have a pair of oblique fold lines 43 extending convergently andlongitudinally thereacross toward the intermediate secondary partitionsto intersect the arched cut lines 17 and 1S. Oblique fold lines 43 de-vfine a pair of hingedly connected lateral edge portions 44 thereinadapted to be wedged against the inner side panels 8 and the outer sidepanels 10 in the erected carton. Similarly, a pair of oblique fold lines45 are provided in each of the secondary' partition panels 32 and 33 andare parallel to the oblique fold lines 43 in proximate respectiveprimary cross partitions, the oblique fold lines 4S providing additionalpairs of lateral edge portions 46 also adapted to be wedged against theside panels 8 and 1t).

The bottom panels 9 of each subsection for each facsimile section have apair of lugs 47 for the adjacent short side panel 8, and a pair oflocking iiaps 43 and 49 for the primary cross partitions 15 and 16. Thelugs and locking flaps are defined by transverse cut lines or slits 51and 52 in the bottom panel which are substantially in alignment with theprimary transverse fold lines 26 and 27, the transverse slits 51 and 52being yadapted to receive the lower ends of the primary crosspartitions. Abbreviated longitudinal cut lines 55 and 56 intersect thetransverse slits 51 and 52 medially of the extremities thereof, andextend, respectively, in directions opposite to those of the terminalsof the proximate arched cut lines 18 and 19. A pair of third cut lines57 and 58 are provided in each bottom panel between the respectiveabbreviated longitudinal cut lines 55 and 56, and the proximate edge ofthe short side panel 8. The locking flaps 48 and 49 are foldablyconnected to the bottom panel along a pair of oblique perforated foldlines 61 and 62 converging transversely toward the short side panel 8and forming continuations of third cut lines 57 and 58, respectively,the fold lines 61 and 62 being offset in an inboard direction from thetransverse slits 51 and 52. Thus, the lugs 47 are adapted to form evencontinuations of the inner side panels 8, while the locking aps 48 and49 are hingedly connected to the bottom panel for wedging againstythelower ends of the respective primary cross partitions to be inserted inthe transverse slits 51 and 52. p

The carton blank in Fig. l is glued and folded into a collapsiblecellular carton in the following manner: The iiaps 6 for each of thefacsimile sections 1 and 2 are glued on one face. The glued ap 6, theshelf panel 7 and the side panel 8 are then folded inboard as one, ineach facsimile section, to overlie the bottom panel 9 and the secondside panel 10, as shown in Fig. 2. As a result of the iirst foldingoperation, the supporting lugs 47 break away from the planes of thebottom panels 8, and the glued aps 6 are adhesively secured torespective inboard portions ofthe second side panels 10. Thereafter, oneor both of the shorter side panels 8 are glued on the face of the blankopposite the first glued face, and the blank ,sections are folded aboutthe frangible cut line 3 to juxtapose the short side panels 8 and theshelf panels 7 of the facsimile sections 1 and 2 into face-to-facecontact, as shown in Fig.v 3. A knife is inserted between the majorpanels during the second folding operation, and the frangibleconnections along the cut line 3 between the tongue flaps 12 aresevered, as shown in Fig. 4. Any knockout sections, not already removedfrom the blank during formation of the major panels therein and lduringkning of the frangible connections between tongue flaps 12, areadvantageously removed by punching the border of the blank in Fig. 3. v

The collapsed carton is erected into the condition shown in Figs. 5-7 byrst squeezing the longitudinal edges of the tongue aps 12 and the bottompanels 9. The major panels break away from each other, as shown in Fig.4. The primary cross partitions 15 and 16 in the shelf panel 7 arefolded downwardly along their primary transverse fold lines 26 and 27; amachine may be employed to open the primary cross partitions as well asthesecondary partitions, for each row of cells. In folding the primarycross partitions 15 and 16, their lower ends slide over the locking aps48 and 49 therefor into the transverse slits 51 and 52. The lockingflaps may then be wedged against the faces of the primary crosspartitions to retain the same between the edges of the locking flaps andthe transverse slits.

The eggs are inserted into the cells between the primary crosspartitions and the downwardly folded pairs of secondary partitions 32and 33. A number of the cross slits 65 are provided in the bottom panels9 to accommodate the eggs, the bottom panels being slanted upwardlyabove the supporting plane for the carton by lugs 47. The top covers 11are folded to interlock the tongue ilaps 12 with the webs defined in theshelf panels 7.

It will be noted that the lateral edge portions 44, in wedgingresiliently against the side panels 8 and 10, lie normal to the planesof the primary cross partitions and resist the tendency thereof to foldalong the grain of the paperboard. For this purpose, the relative panelwidths for each facsimile section of the blank are such that each of theshelf panels 7 in the erected carton slopes downwardly from the verticalinner side panels 8 to the converging outer side panels 10, so that boththe primary cross partitions and the secondary partitions folddownwardly at a slight inclination to the inner side panels. The inneroblique fold lines 43 and 45 for the primary cross partitions and thesecondary partitions thereby ride over the vertical faces of the innerside panels 8, while providing a substantial area for each of therespective inner lateral edge portions 44 and 46 for resisting bendingofthe partitions. Likewise, the 'outer oblique fold lines 43 and 45 forthe partitions ride over the faces of the converging outer side panels10, and the respective outer lateral edge portions 44 and 46 fold fromthe planes of the partitions in contacting the outer side panels suchthat the lateral edge portions are of sufficient size to resist bendingof the partitions. The locking flaps 48 and 49, wedged against the lowerends of these primary cross partitions, further serve to stilen byproviding edge-toedge support between the transverse slits 51 and 52 andthe locking aps. The pairs of lugs 47, forming even continuations forthe shorter abutting inner side panels 8, provide even edges lying inthe plane of the lower ends of the cross partitions as well as thesupporting plane for the carton. Structural soundness of the primarycross partitions provides rigidity for stacking the cartons one abovethe other, thereby assisting the supporting lugs 47 in providing uniformcontact between superposed cartons.

It will also be noted that erection of the primary cross partitions 15and 16 is facilitated by the gradual entry provided therefor by the lockaps 48 and 49 as they fold along their hinged connections at 61 and 62.These latter connections, being oblique to the forward edge of theprimary 'cross partitions, and being offset from the transverse slits 51and 52, allow substantial clearance for passage of the cross partitionsthrough the bottom pail-els.

Preferably, the major panels are integrally connected by series ofcut-score lines, although the connections between the bottom'panels 9and the inner short side panels 8 are neither cut nor scored to provideresiliency between the panels. This contributes to ease of erection ofthe carton. By reason of the rigid character of the primary crosspartitions 15 and 16, severance of the erected carton transversely alongthe cut line 4 of the blank sections does not impair compartmentationfor intermediate cells. The transversecut line 4 includes a series ofperforated portions in the external major panels, and cut lines for thein-v ternal major panels (the bottom panels 9, the shelf panels 7,andthe glue flaps 6), the corners of the external major panels at cutline 4 being cut to facilitate halving of the erected carton. Prior toseverance, the eggs are maintained spaced in each row of `cells both bythe secondary partitions between each pair of the primary crosspartitions 15 and 16, and the double wall between proximate pairs ofprimary cross partitions. The arrangement of partitions in the shelfpanels of the blank eliminates waste of paperboard normally experiencedwhere the primary cross partitions extend throughout in the samedirection, and, consequently, require a projecting end wall panel beyondthe balance of the rectangular outline yof the carton Iblank.

Instead of the arrangement of primary cross partitions and secondarypartitions of the blank in Fig. l, the blank may be designed to erectinto a carton for carrying a full dozen eggs, for example, withoutseverance of the 2 x 6 carton. Fig. 8 illustrates such an arrangementfor the blank wherein a plurality of pairs of primary cross partitionsare advantageously arranged at both sides of an intermediate pair oftransverse partitions. The reference characters used for the blank inFig. 8 are identical with those in Fig. l, the only departure from thefirst modification being the number and the arrangement of partitions ineach shelf panel. In this latter modification the number of lockingiiaps 48 and 49 may also be correspondingly increased to providerigidity for the increased number of primary cross partitions. Theessential arrangement for the'carton blank of Fig. 8 therefore, remainssubstantially the equivalent of the partition arrangement in Fig. l.Thus, as shown in Fig. 7, the shelf panels 7 of the erected carton eachincludes at least a pair of oppositely and inwardly extending primarycross partitions with at least a pair of secondary partitions beingformed in the shelf' panel intermediate the primary cross partitions.

y Each' of the top cover panels 12 may have its transverse edgesindented at 68 adjacent the foldable connection thereof with the sidepanel 10. A carton is opened by r gripping the indented section of thecover panel, with the proximate edge of a side wall 10 as support, andpulling upwardly. The leverage gained thereby unlocks the tongue flap 12from the shelf panel 7 in each row of cells.

Thus, I have provided an egg carton having a blank wherein the majorpanels are defined with a minimum of paperboard material. Any wastecutouts and knockout sections remaining attached to the blank, and notremoved incidental to folding of the major panels, are advantageouslyremoved from the border of the folded blank rather than from lessaccessible inner portions of the blank. The partitions folded downwardlyinto the erected carton are stiifened against bending along the grain ofthe paperboard, both by the lateral edge portions of the partitions, andby the transverse slits and locking aps in the bottom panels. At thesame time, the hinged connections of the primary and secondarypartitions to the shelf panels are flexible enough to resilientlyaccommodate eggs of varying size. The partition arrangement in eachcarton section is such that the carton sections can be halved leavingintermediate primary cross partitions having substantially the strengthof carton end walls.

I claim:

1. A paperboard collapsible carton having a pair of longitudinallyconnected abutting sections forming a pair of rows of cells with eachrow composed of at least one 7 group of 'three cells dened by one pairof primary cross partitions and an vintermediate pair of secondary'partitions, `said carton comprising a pair of inner' panels adhesive'lysecured together 'in side-by-side' relation, a bottom panel integrallyconnected tol the lower edge of each inner side panel, an outer sidepanel Vintegrally connected to the outer edge of each bottom panel andextending upwardly and outwardly from the bottom panel, the height ofeach of the inner side panels beingi'less than the height of each outerside panel, ra shelt panel-integrally connected at its inner edge to theupper edge of-each inner side panel and adhesively connected at litsouter edge to the proximate outer side panel, the width of each shelt`panel being greater than 'the width of eachbott'om'ipanel, at least onepair of oppositely extending primary cross partitions formed from Vthefull Width-of each shelf panel,

each primary cross partition being folded downwardly fromthc plane ofits shelf panel about a transverse Afold line, at least one pair ofsecondary partitions being formed ine'ach shelf panel intermediate thepair of primary cross partitions and being folded downwardly `into theerected carton about transverse fold lines spacedtrom 'one 'another adistance equal to their respective distance from the proximatetransverse fold line for said primary cross partitions, the two primarycross partitions and the two secondary cross partitions being formedfrom the portion of the shelf panel between the two transverse foldlines for said primary cross partitions, a pair of oblique fold lines ineach of the primary cross partitions and the secondary partitionsconverging vfrom the lateral extremities of the transverse fold linesfor their respectivezpartitions along the inner and outer side panelstoward the bottom panels, lateral edge portions of the primary crosspartitions and the secondary partitions being folded inwardly from theplanes thereof as a result of the partitions being folded about theirrespective transverse fold lines, said lateral edge portions beingwedged against the inner and outer side panels along said oblique foldlines, each bottom panel having transverse slits therein for receivingthe lower end of each primary cross partition lof 'each pair thereof,and a pair of lugs cut yfrom each bottom panel and forming continuousprojections from the lower edge of and coplanar with each inner sidepanel.

2. A paperboard blank for a collapsible cellular carton 'having a pairof facsimile sections frangibly connected along an interruptedlongitudinal cut line, each facsimile section of the blank comprising inintegrally connected inboard succession an Vouter glue flap, a shelfpanel, an inner side panel, a bottom panel having a width less than thewidth of the shelf panel, an outer side panel wider than the 'inner sidepanel and adapted to' receive said outer glue ilap in 'jnxtapositiom 'atop cover panel, and a tongue llap, the tongue 'flaps for said facsimilesections being laterally adjacent alongfsaid interrupted longitudinalcut line, each shelf panel being provided with at least one pair ofVspaced oppositely extending primary cross partitions hinged to' theshelf panel by a pair of primary transverse fold lines and formed fromthe full width of the `shelf panel, each shelf panel being furtherprovided with at least one pair of secondary partitions positionedintermediate the pair of primary cross pa'rtitions and also formed fromthe full width of the shelf panel, the secondary partitions of each pairthereof being hinged to the shelf panel along secondary transverse foldlines spaced longitudinally from one another a distance equal to thedistance between proximate primary and secondary transverse fold lines,the two primary cross partitions and the two secondary cross partionsbeing formed from the' portion of the shelf panel between the twotransverse fold lines for said primary cross partitions, a pair -ofoblique fold lines in each of the primary cross partitions and thesecondary partitions converging from the lateral extremities of theirrespective primary and secondary transverse fold lines across thepartitions and adapted to bear evenly against said inner and outer sidepanels when said partitions are folded downwardly into the carton, eachof said bottom panels having transverse slits -therein adapted toreceive thelower end ofeach primary cross partition of each pairthereof, and at least one pair of lugs dened in each bottom panel byarched cut lines adjacent each of said inner side'panels, a primarycross partition-locking flap foldably connected to the bottom panelalong an oblique transverse fold line olset from but converging towardthe inboard end of each transverse slit.

References Cited in the le of this patent Buttery AJuly 14, 1953

